Unitary dental model

ABSTRACT

Improved dental models for use in dental procedures are provided. In one aspect, a unitary dental model of an intraoral cavity of a patient having a dental implant comprises a physical surface representative of gingival tissue of the patient. The model can comprise a channel shaped and oriented to receive an abutment corresponding to a physical abutment to be connected to the dental implant, in which the channel extends to an opening in the physical surface. The channel can comprise a first portion shaped to receive and constrain a corresponding structure of the abutment to a position and orientation and a second portion shaped to receive a fastener to couple the abutment to the unitary dental model. In many embodiments, the first portion comprises a shoulder shaped to receive the corresponding structure of the abutment in order to position the abutment along the channel.

CROSS-REFERENCE

This application is a continuation of U.S. application Ser. No.16/006,183, which is a divisional of U.S. application Ser. No.14/306,096, filed Jun. 16, 2014, now U.S. Pat. No. 10,016,262, issuedJul. 10, 2018, which are incorporated herein by reference in theirentirety, and to which applications we claim priority under 35 USC §121.

BACKGROUND

Dental implants are widely used as artificial substitutes for the rootportion of missing teeth. A dental implant allows a dental restoration,such as a dental prosthesis, to be securely anchored to the jaw via anabutment mounted to the implant. An endosseous implant may have anexternally threaded body. The threaded body can be configured forself-tapping into the bone tissues of the jaw. An endosseous implant canhave an internal passage that is configured, such as internallythreaded, for receiving and securing the anchoring stem of a permanentabutment therein.

Following implantation of an implant in the intraoral cavity and healingof the surrounding tissues, a physical model of the intraoral cavity isproduced for facilitating design and manufacture of the permanentabutment and prosthesis that are to be mounted onto the implant. In oneprocedure, an analog is placed in the physical model that is similar tothe patient's intraoral cavity. The analog can be configured with aninternal passage similar to the internal passage of the implant forreceiving and securing the permanent abutment. The dental technician canthen use the physical model to design and/or build a dental prosthesisfor the patient. The dental technician mounts an abutment to thephysical model via the internal passage of the analog. The dentaltechnician then proceeds to build a dental prosthesis to fit onto theabutment and match surrounding teeth in the intraoral cavity of thepatient.

The methods and apparatus for constructing dental models can be lessthan ideal in at least some instances. Accurate placement of the analogin the physical model can be important for correct design andmanufacture of the permanent abutment and prosthesis, and also for theoutcome of the dental procedure. Accurate placement of an analog into aphysical dental model, however, can be difficult. For example, manualpositioning and orientation of an analog can be less than ideal withrespect to accuracy, outcome and user convenience. In some dentalmodels, which may employ a separate implant analog that is separatelycoupled to the dental model, inaccuracies in the placement of suchimplant analogs may compromise the accurate positioning of the abutment,and therefore degrade the accuracy of the prosthesis subsequentlyfabricated on the abutment and model.

Thus, there is a need for improved dental models for dental proceduresinvolving a dental implant. Ideally, such improved models would besimple to use, provide improved outcomes, include relatively fewdiscrete parts, and provide accurate positioning and orienting of thepermanent abutment.

SUMMARY

Embodiments of the present invention provide improved dental models andmethods for dental procedures. The embodiments disclosed herein simplifythe coupling of an abutment for a dental implant to a physical dentalmodel, thereby enhancing the accuracy and ease of placement of theabutment in the model. In many embodiments, a unitary dental model of apatient's intraoral cavity comprises integrally formed structures shapedto position and orient the abutment relative to the model, and theposition and orientation may comprise a predetermined position andorientation. The unitary model may comprise integrally formed structuresshaped to receive a fastener in order to secure the abutment to thedental model. These structures can facilitate direct coupling of theabutment to the dental model in a configuration corresponding to theconfiguration of the abutment and implant in the patient's intraoralcavity, so as to provide an accurate model of abutment placement in theintraoral cavity suitable for use in dental prosthesis design andfabrication. Direct fabrication of a physical model having thestructures described herein can decrease the number of steps performedto couple a separate implant analog to a physical model of a patient'sdentition, which can reduce the probability of error associated withmanual analog placement and providing for simpler and more accuratedesign and/or fabrication of dental prostheses mounted to dentalimplants.

Thus, in one aspect, a unitary dental model of an intraoral cavity of apatient having a dental implant is provided. The model comprises aphysical surface representative of gingival tissue of the patient. Themodel can comprise a channel shaped and oriented to receive an abutmentcorresponding to a physical abutment to be connected to the dentalimplant, in which the channel extends to an opening in the physicalsurface. The channel comprises a first portion shaped to receive andconstrain a corresponding structure of the abutment to a position andorientation and a second portion shaped to receive a fastener to couplethe abutment to the unitary dental model. In many embodiments, the firstportion comprises a shoulder shaped to receive the correspondingstructure of the abutment in order to position the abutment along thechannel.

Other objects and features of the present invention will become apparentby a review of specification, claims, and appended figures.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1A illustrates a portion of a patient's intraoral cavity having animplant, in accordance with many embodiments;

FIG. 1B illustrates a scan body or impression body coupled to animplant, in accordance with many embodiments;

FIG. 1C illustrates an abutment coupled to an implant, in accordancewith many embodiments;

FIG. 2A illustrates a unitary dental model of an intraoral cavity withan implant, in accordance with many embodiments;

FIG. 2B is a cross-sectional view of the model of FIG. 2A, in accordancewith many embodiments;

FIG. 2C is a cross-sectional view of the model of FIG. 2A illustratingan abutment mounted thereto, in accordance with many embodiments;

FIG. 2D illustrates a cross-sectional view of the model of FIG. 2Aillustrating an abutment and dental prosthesis mounted thereto, inaccordance with many embodiments;

FIG. 3 illustrates a display showing a virtual model of a patient'sintraoral cavity, in accordance with many embodiments;

FIG. 4 illustrates a method for creating a unitary dental model of apatient's intraoral cavity, in accordance with many embodiments;

FIG. 5A illustrates a unitary dental model fabricated using a millingprocess, in accordance with many embodiments;

FIG. 5B is a top view of the of the unitary dental model of FIG. 5A, inaccordance with many embodiments;

FIG. 6 illustrates a method for creating a virtual model of a patient'sintraoral cavity, in accordance with many embodiments; and

FIG. 7 illustrates a system for creating a unitary dental model, inaccordance with many embodiments.

DETAILED DESCRIPTION

A better understanding of the features and advantages of the presentdisclosure will be obtained by reference to the following detaileddescription that sets forth illustrative embodiments, in which theprinciples of embodiments of the present disclosure are utilized, andthe accompanying drawings.

Although the detailed description contains many specifics, these shouldnot be construed as limiting the scope of the disclosure but merely asillustrating different example and aspects of the present disclosure. Itshould be appreciated that the scope of the disclosure includes otherembodiments not discussed in detail above. Various other modifications,changes, and variations which will be apparent to those skilled in theart may be made in the arrangement, operation, and details of theembodiments of the present disclosure provided herein without departingfrom the spirit and scope of the invention as described herein.

As used herein A and/or B encompasses one or more of A, or B, andcombinations thereof such as A and B.

The embodiments disclosed herein can be combined in one or more of manyways to provide improved dental models for use in various dentalprocedures. A unitary dental model of a patient's intraoral cavityhaving one or more dental implants can comprise a channel having a firstportion shaped to receive and constrain an abutment to a position andorientation and a second portion shaped to receive a fastener forcoupling the abutment to the model. The structures of the channel in thedental model can facilitate placement of the abutment with greateraccuracy and using fewer parts. The methods and systems described hereincan decrease additional components and/or interfaces to mount a separateimplant analog to a physical model of the patient's dentition.

While the present description is directed to a single implant, theembodiments described herein can be used to create virtual and physicaldental models of an intraoral cavity with any number of dental implants.For example, some embodiments described herein can be used with aplurality of implants that are functionally independent from one another(e.g., being used for separate prostheses). Alternatively or incombination, some embodiments can be used with a plurality of implantswhere at least some of the implants are functionally dependent (e.g.,being used together for a bridge prosthesis or other prostheses spanningmultiple teeth). Exemplary dental prostheses suitable for use with theembodiments disclose herein include crowns, bridges, dentures, or anyother abutment-supported prosthetic devices, for example.

In many embodiments, a unitary dental model of an intraoral cavity of apatient having a dental implant is provided. The model can include aphysical surface representative of gingival tissue of the patient. Themodel can also include a channel shaped and oriented to receive anabutment corresponding to a physical abutment to be connected to thedental implant, the channel extending along to an opening in thephysical surface. The channel may comprise a first portion shaped toreceive and constrain a corresponding structure of the abutment to aposition and orientation within the first portion, and a second portionshaped to receive a fastener to couple the abutment to the unitarydental model. In many embodiments, the first portion comprises ashoulder shaped to receive the corresponding structure of the abutmentin order to position the abutment along the channel.

The design of the unitary dental model may be varied as desired. Forinstance, in many embodiments, the physical surface comprises physicalmodels of one or more teeth and a physical model of gingival tissueextending between the one or more teeth. The physical models of the oneor more teeth may be representative of one or more teeth of theintraoral cavity near the implant, such as one or more teeth adjacentthe implant site. The opening can comprise a maximum cross-sectionaldimension sized larger than a maximum cross-sectional dimension of thesecond portion. The first portion can be shaped to correspond to aportion of the dental implant that receives and constrains acorresponding portion of the physical abutment. The second portion canextend to an opening in a bottom surface opposite the physical surface.The opening in the bottom surface can be shaped to accommodate a nut forsecuring the abutment and fastener to the unitary dental model.

As described above, the unitary dental model can be configured to engagean abutment so as to constrain it to a desired position and orientation.In many embodiments, the first portion is shaped to receive andconstrain the corresponding structure of the abutment to a predeterminedposition and orientation. The predetermined position and orientation maycorrespond to a position and orientation of the physical abutment whenconnected to the dental implant in the intraoral cavity. The channel maybe an elongate channel comprising a longitudinal axis, and thepredetermined position and orientation can be defined by one or more ofthe longitudinal axis, shoulder, or opening. The predeterminedorientation may comprise a rotation about the longitudinal axis or arotation away from the longitudinal axis. In many embodiments, thecorresponding structure of the abutment comprises a lower engagementsurface and the shoulder is shaped to receive and mate with the lowerengagement surface in order to position the corresponding structure at alocation along the longitudinal axis. Optionally, the model can includethe abutment comprising the corresponding structure comprising the lowerengagement surface

In many embodiments, a computer-implemented method for creating avirtual model of an intraoral cavity of a patient having a dentalimplant is provided. The method comprises receiving three-dimensional(3D) topographical data of the intraoral cavity having the dentalimplant. A virtual model can be generated with the 3D topographicaldata. The virtual model can comprises a virtual surface representativeof gingival tissue of the patient and a channel shaped and oriented toreceive a virtual abutment model corresponding to one or more of aphysical abutment to be connected to the dental implant or an abutmentto be connected to a unitary dental model fabricated from the virtualmodel. The channel can extend to an opening in the surface and cancomprise a first portion and a second portion. The first portion can beshaped to receive and constrain a corresponding structure of the virtualabutment model to a position and orientation. The second portion can beshaped to receive a virtual fastener model corresponding to a fastenerused to couple the abutment to the unitary dental model. The firstportion can comprise a shoulder shaped to receive the correspondingstructure of the virtual abutment model in order to position the virtualabutment model along the channel.

Various techniques can be used to create the virtual models describedherein. For instance, the step of using the 3D topographical data tocreate a virtual model may comprise positioning a virtual model of animplant analog relative to an as-scanned 3D virtual model that embodiesthe 3D topographical data of the intraoral cavity having the implant sothat the implant analog virtual model matches the position andorientation of the implant in the as-scanned 3D virtual model. Theas-scanned 3D virtual model can be modified by merging the implantanalog virtual model with the as-scanned 3D virtual model, therebycreating a modified as-scanned model. Furthermore, using the 3Dtopographical data to create a virtual model may further comprisesubtracting an extraction virtual model from the modified as-scannedmodel so as to at least one of: a) create the second portion of thechannel shaped to receive the virtual fastener model, and b) remove oneor more virtual model elements corresponding to a scan body or animpression body coupled with the implant in the as-scanned virtualmodel.

In many embodiments, a method for creating a unitary dental model of anintraoral cavity of a patient having a dental implant is provided. Themethod comprises receiving 3D topographical data of the intraoral cavityhaving the implant and fabricating the unitary dental model with the 3Dtopographical data. The unitary dental model can comprise a physicalsurface representative of gingival tissue of the patient. The model canalso comprise a channel shaped and oriented to receive an abutmentcorresponding to a physical abutment to be connected to the dentalimplant, the channel extending to an opening in the physical surface.The channel can comprise a first portion shaped to receive and constraina corresponding structure of the abutment to a position and orientation,and a second portion shaped to receive a fastener to couple the abutmentto the unitary dental model. In many embodiments, the first portioncomprises a shoulder shaped to receive the corresponding structure ofthe abutment in order to position the abutment along the channel.Optionally, the method may further comprise mounting the abutment to theunitary dental model via the first portion of the channel and securingthe abutment to the unitary dental model using the fastener receivedwithin the second portion of the channel.

In many embodiments, the unitary dental model can be created based on avirtual model. For example, the step of using the 3D topographical datato fabricate the unitary dental model may comprise positioning a virtualmodel of an implant analog relative to an as-scanned 3D virtual modelthat embodies the 3D topographical data of the intraoral cavity havingthe implant so that the implant analog virtual model matches theposition and orientation of the implant in the as-scanned 3D virtualmodel. The as-scanned 3D virtual model can be modified by merging theimplant analog virtual model with the as-scanned 3D virtual model,thereby creating a modified as-scanned model. Furthermore, using the 3Dtopographical data to create a virtual model may further comprisesubtracting an extraction virtual model from the modified as-scannedmodel so as to at least one of: a) create the second portion of thechannel shaped to receive the virtual fastener model, and b) remove oneor more virtual model elements corresponding to a scan body or animpression body coupled with the implant in the as-scanned virtualmodel. Optionally, using the 3D topographical data to create a virtualmodel may further comprise modifying one or more portions of themodified as-scanned model in order to provide a desired amount ofclearance between the first portion and the corresponding structure ofthe abutment. The fabricating step may be performed using acomputer-controlled material removing process.

In many embodiments, a system for modeling of an intraoral cavity of apatient having a dental implant is provided. The system includes one ormore processors and memory storing instructions executable by the one ormore processors. The instructions may cause the one or more processorsto receive 3D topographical data of the intraoral cavity having theimplant and generate a virtual model with the 3D topographical data. Thevirtual model can comprise a virtual surface representative of gingivaltissue of the patient and a channel shaped and oriented to receive avirtual abutment model corresponding to one or more of a physicalabutment to be connected to the dental implant or an abutment to beconnected to a unitary dental model fabricated from the virtual model.The channel can extend to an opening in the surface and can comprise afirst portion and a second portion. The first portion can be shaped toreceive and constrain a corresponding structure of the virtual abutmentmodel to a position and orientation. The second portion can be shaped toreceive a virtual fastener model corresponding to a fastener used tocouple the abutment to the unitary dental model. The first portion cancomprise a shoulder shaped to receive the corresponding structure of thevirtual abutment model in order to position the virtual abutment modelalong the channel.

In many embodiments, the instructions may cause the one or moreprocessors to position a virtual model of an implant analog relative toan as-scanned 3D virtual model that embodies the 3D topographical dataof the intraoral cavity having the implant so that the implant analogvirtual model matches the position and orientation of the implant in theas-scanned 3D virtual model. The as-scanned 3D virtual model can bemodified by merging the implant analog virtual model with the as-scanned3D virtual model, thereby creating a modified as-scanned model.Furthermore, using the 3D topographical data to create a virtual modelmay further comprise subtracting an extraction virtual model from themodified as-scanned model so as to at least one of: a) create the secondportion of the channel shaped to receive the virtual fastener model, andb) remove one or more virtual model elements corresponding to a scanbody or an impression body coupled with the implant in the as-scannedvirtual model.

In many embodiments, the instructions can cause the one or moreprocessors to generate output configured to control a fabricationmachine to fabricate a unitary dental model corresponding to the virtualmodel.

Turning now to the drawings, in which like numbers designate likeelements in the various figures, FIG. 1A illustrates a portion of apatient's intraoral cavity 100 having an implant 102, in accordance withmany embodiments. The implant 102 is positioned at an implant site 104in the tissue of the intraoral cavity. The implant 102 can be a screw,post, cylinder, or any other device suitable for serving as an anchorfor a dental prosthesis. The implant site 104 may correspond to thelocation of one or more missing teeth to be replaced by the dentalprosthesis to be coupled to the implant 102. The implant site 104 can belocated within the gingival tissue 106 extending between one or moreteeth 108. Alternatively, the implant site 104 can be located within awholly edentulous portion of the intraoral cavity, such that there areno teeth adjacent to or near the gingival tissue 106.

In many embodiments, the implant 102 includes a coupling interface 110that is exposed from the surrounding gingival tissue 106. The couplinginterface 110 can include structures suitable for coupling the implant102 to a discrete component, such as a healing abutment, scan body,impression body, temporary abutment, or permanent abutment. Thestructures of the coupling interface 110 can be shaped to mate withcorresponding structures of the discrete component, and can include anysuitable combination of sockets, channels, apertures, grooves, notches,threads, and so on.

FIG. 1B illustrates a scan body or impression body 112 coupled to theimplant 102, in accordance with many embodiments. The scan body orimpression body 112 can be coupled to the implant 102 via the couplinginterface 110. The scan body or impression body 112 may protrude abovethe gingival tissues 106 such that its arrangement relative to theintraoral cavity can be captured using an intraoral scan or dentalimpression, respectively. The scan body or impression body 112 caninclude structures 114 enabling the position and orientation of theunderlying implant 102 relative to the intraoral cavity to be determinedbased on the position and orientation of the structures 114. Forinstance, the structures 114 can include a shape or structure of thebody 112 (e.g., an asymmetric shape), coloring, marks, symbols,characters, or any other visual markings or physical structures suitablefor use with the body 112. The scan body or impression body 112 can beused in conjunction with intraoral scanning techniques or dentalimpression techniques, respectively, to produce topographical data ofthe intraoral cavity 100, as well as position and orientationinformation for the implant 102, as discussed in further detail below.

FIG. 1C illustrates an abutment 116 coupled to the implant 102, inaccordance with many embodiments. In many embodiments, the implant 102serves as an anchor for a dental prosthesis such as a bridge or crown.The abutment 116 can serve as a support for the dental prosthesis aswell as a connector for fastening the prosthesis to the implant. In manyembodiments, the abutment 116 is coupled to the implant 102 (e.g., viathe coupling interface 110), and the prosthesis (not shown) is mountedonto the abutment 116. The abutment 116 can be any suitable abutment fora dental procedure, such as a stock abutment manufactured with apredefined shape. Alternatively, the abutment 116 can be a customabutment designed specifically for the patient. In many embodiments, theabutment 116 is manufactured through a computer-controlled process. Theabutment 116 can be created based on the 3D data of the intraoral cavityand/or virtual modeling techniques, such as the techniques describedherein, to ensure proper positioning and fit within the patient'sintraoral cavity. The abutment 116 can be further modified to engage aportion of a dental prosthesis. For example, the upper surface of theabutment 116 can be refined as appropriate to interface with an interiorsurface of a crown to be seated onto the abutment 116.

In many embodiments, the abutment 116 is situated at a specifiedposition and orientation relative to the intraoral cavity 100 (e.g.,teeth 108, gingival tissues 106). The position and orientation of theabutment 116 may be determined based on the position and orientation ofthe implant 102 within the intraoral cavity 100. For example, thecoupling interface 110 of the implant 102 can be shaped to receive acorresponding structure of the abutment 116 (e.g., a base portion of theabutment 116). The engagement between the coupling interface 110 and thecorresponding structure of the abutment 116 can constrain the abutment116 to the desired position and orientation.

As previously described, dental prostheses for an intraoral implant canbe fabricated using a physical model of the patient's intraoral cavity.The use of such dental models allows such prostheses to be designed inconformance with the geometry of the intraoral tissues near the implantsite (e.g., adjacent teeth and gingiva) so as to avoid collisions orinterference, ensure proper bite registration, and provide the desiredaesthetic appearance. During the prosthesis design process, theprosthesis can be mounted to the dental model via an abutment placed inthe model. The abutment may correspond to or be the actual physicalabutment that will be connected to the implant in the patient'sintraoral cavity. The position and orientation of the abutment relativeto the intraoral tissues represented in the model may correspond to theposition and orientation of the actual abutment relative to the adjacentintraoral tissues when connected to the implant in the intraoral cavity.

In many embodiments, the dental models provided herein includeintegrally formed structures shaped and oriented to receive theabutment, such as a suitably shaped channel, cavity, passage, etc. Theintegrally formed structures can be designed to engage with andconstrain the coupled abutment to a specified position and orientation.For example, the structures can include any suitable combination ofshoulders, stops, recesses, notches, grooves, protrusions, or other suchregistration structures or features configured to engage and retain theabutment at the specified position and orientation. The position andorientation of the coupled abutment may be predetermined based on theposition and orientation of the actual physical abutment when connectedto the implant, as described above. Notably, the use of such integrallyformed structures enables the abutment to be directly coupled to themodel, thereby obviating the need for implant analogs that are placedinto the model to interface with the abutment. Accordingly, embodimentsof the models presented herein may be considered to be “unitary” models,in that the structures receiving and constraining the abutment to thedesired position and orientation are integral with the model and notprovided separately as discrete components.

In many embodiments, the integrally formed structures correspond to thecorresponding structures of the implant coupling interface that engagethe abutment. Any structure or combination of structures suitable forregistering the abutment to a specified orientation and position can beused. For example, the structures can include a cavity defining a shapeof at least a portion of the implant (e.g., the coupling interface ofthe implant). The structures can be symmetric or asymmetric, and canform a single continuous shape or multiple discontinuous shapes. Thestructures can include any suitable markers or indicators, for example,to aid a user in aligning and mounting the abutment onto the physicalmodel.

FIGS. 2A and 2B illustrate a unitary dental model 200 of an intraoralcavity with an implant, in accordance with many embodiments (FIG. 2B isa cross-sectional view of FIG. 2A). The unitary dental model 200 may bea positive physical model of the patient's intraoral cavity. The dentalmodel 200 can depict any suitable portion of the patient's intraoralcavity, such as a portion of a dental arch (e.g., the upper or lowerarch) or the entire dental arch. The dental model 200 can include aphysical surface 202 representative of the patient's intraoral tissuesnear the implant site, such as gingival tissues 204. Optionally, thephysical surface 202 can also include one or more tooth models 206corresponding to teeth near the implant site. The physical surface 202may be the upper surface of the dental model 200. The dental model 200can also include a bottom surface 208 opposite the physical surface 202forming part of a model base that supports the model 200 (e.g., whenplaced on a table, workbench, or other work surface).

In many embodiments, the model 200 includes a channel 210 formed at ornear the implant site and shaped and oriented to receive an abutment.The channel 210 can be an elongate channel having a longitudinal axis212. The channel 210 can extend at least partially through the thicknessof the model 200 along the longitudinal axis 212. For example, a firstend of the channel 210 can extend to an opening 214 in the physicalsurface 202. The opposing second end of the channel 210 can extend to anopening 216 in the bottom surface 208, such that the channel 210 extendsthrough the entire thickness of the model 200. Alternatively, the secondend of the channel 210 may not be connected to the bottom surface 208,such that the opening 216 is absent and the channel 210 extends onlypartially through the thickness of the model 200. The channel 210 caninclude a first portion 218 and a second portion 220. The first portion218 can be connected to the opening 212 and can be configured to receiveat least a portion of the abutment. For instance, the first portion 218can include a shoulder 222 or other mechanical stop structure shaped toreceive a corresponding structure of the abutment so as to position italong the channel 210. The second portion 220 can be connected to thefirst portion 218 via the shoulder 222 and can be shaped to receive afastener for securing the abutment to the model 200. The maximumcross-sectional dimension (e.g., diameter) of the opening 214 and/orfirst portion 218 may be larger than the maximum cross-sectionaldimension of the second portion 220. Optionally, the second portion 220can be connected to the opening 216 in the bottom surface 208. Theopening 216 can be shaped to receive a second fastener for securing theabutment.

FIG. 2C illustrates an abutment 224 coupled to the unitary dental model200, in accordance with many embodiments. Various components of themodel 200 (e.g., channel 210, longitudinal axis 212, opening 214, and/orfirst portion 218) can be configured to constrain the abutment 224 to aposition and orientation when mounted to the model 200 (e.g., apredetermined position and orientation as described above). The positionand orientation of the abutment 224 can be defined with respect to up tosix degrees of freedom of movement (e.g., three degrees of translation,three degrees of rotation). For example, the position of the abutment224 may include a translation parallel to the longitudinal axis 212and/or orthogonal to the longitudinal axis 212. As another example, theorientation of the abutment 224 may include a rotation about thelongitudinal axis 212 or away from the longitudinal axis 212.

In many embodiments, the geometry and arrangement of the channel 210,longitudinal axis 212, opening 214, and/or first portion 218 define theposition and orientation of the coupled abutment 224. For example, theshape of the opening 214 and/or the first portion 218 can becomplementary to the shape of a corresponding structure of the abutment224 (e.g., the lower or base portion 226 of the abutment 224) so as todefine the position and orientation of the abutment when it is receivedinto the opening 214 and/or first portion 218. The shape of the opening214 and/or first portion 218 may correspond to the shape of a portion ofthe dental implant (e.g., the coupling interface) that receives andconstrains the abutment structure. In many embodiments, the shoulder 222can be shaped to receive and mate with a lower engagement surface 228 ofa corresponding abutment structure so as to position the abutment alongthe channel 210 (e.g., along the longitudinal axis 212). The shoulder222 may serve as a mechanical stop, such that the depth to which theabutment 224 is inserted along the channel 210 is constrained by thelocation of the shoulder 222. The geometry of the shoulder 222 may becomplementary to the shape of the lower engagement surface 228 of theabutment. One or more portions of the engagement surface 228 may beinclined relative to the longitudinal axis 212, orthogonal orapproximately orthogonal to the longitudinal axis 212, and so on.

The abutment 224 can be coupled to the unitary dental model 200 using afastener 230. The second portion 220 of the channel 210 can be shaped toaccommodate the fastener 230. For example, the second portion 220 caninclude a recess, channel, passage, cavity, etc., which may have ageometry (e.g., length, width, depth, diameter) corresponding to thegeometry of the fastener 230. The fastener 230 can be a screw, bolt,pin, post, cylinder, etc. that passes through the abutment 224 (e.g.,via a hole formed in the abutment 224) and the second portion 220 of thechannel 210 so as to secure the abutment 224 to the model 200. Forexample, fastener 230 may be a self-tapping screw capable of beingfastened to the material of the model 200 surrounding the second portion220. As another example, the fastener 230 may be specifically configuredto be used with the abutment 224, such as a screw that can be also usedto couple the abutment 224 to the implant in the patient's intraoralcavity. In many embodiments, the opening 216 in the bottom surface 208can be shaped to accommodate a second fastener, such as a nut 232. Whenplaced in the model 200, the abutment 224, fastener 230, and nut 232 maybe coaxial or approximately coaxial. The nut 232 can be tightened aroundthe fastener 230 to secure the fastener 230 and abutment 224 to themodel 200. This approach may advantageously permit a generic screw,threaded sleeve, or other fastener to be used to couple the abutment 224without requiring self-tapping. Optionally, the channel 210 can includestructures that permit the abutment 224 to be secured to the model 200without the use of additional fasteners, such as integrated threadingcomplementary to threading on a corresponding structure of the abutment.

FIG. 2D illustrates a dental prosthesis 234 mounted onto the model 200,in accordance with many embodiments. The dental prosthesis 234 caninclude an interior cavity shaped to receive a corresponding structure(e.g., the upper portion) of the abutment 224. As previously described,the dental prosthesis 234 can be fabricated using the model 200 andcoupled abutment 224.

Various methods can be used for the design and fabrication of theunitary dental models described herein. For example, computer-baseddesign methods can be used to develop virtual dental models that aresubsequently used as input for computer-controlled manufacturingprocesses to produce the corresponding physical dental models. The useof such digital design and fabrication methods can provide convenient,flexible, and accurate production of dental models having the featurespresented herein.

FIG. 3 illustrates a display 300 showing a virtual model 302 of apatient's intraoral cavity, in accordance with many embodiments. Thevirtual model 302 can be used to design and fabricate a physical model,such as the unitary dental models provided herein. Accordingly, thevirtual model 302 can include a virtual representation of any of thecomponents of the physical models described herein. For example, thevirtual model 302 can include a virtual surface 304 representative ofintraoral tissues (e.g., virtual gingival tissues, virtual toothmodels). The virtual model 302 can also include virtual structuresshaped and oriented to receive a virtual abutment corresponding to theabutment to be connected to the implant and/or the abutment to beconnected to the unitary dental model. For instance, the virtual model302 can include a channel 306 extending to an opening 308 in the virtualsurface 304, and optionally to an opening (not shown) in a virtualbottom surface 310 of the virtual model 302. The channel 306 can includeany of the structures and features previously discussed herein, such asa first portion, second portion, shoulder, longitudinal axis, etc.

FIG. 4 illustrates a method 400 for creating a unitary dental model of apatient's intraoral cavity, in accordance with many embodiments. Themethod 400, as with all methods described herein, can be used incombination with any of the devices and systems described herein.

In step 410, three-dimensional (3D) topographical data of an intraoralcavity having an implant is received. The 3D topographical data caninclude any suitable surface of the intraoral cavity, such as a completedentition, a partial dentition, and/or gingival tissues. In manyembodiments, the 3D topographical data can include 3D topographical dataof a suitable device coupled to the implant, such as an impression bodyor a scan body. As previously described, an impression body or scan bodymay include structures from which the orientation and position of theunderlying implant can be determined relative to the patient's intraoralcavity.

The 3D topographical data can be obtained using any suitable method,such as an intraoral scan of the patient's dentition and implant. Inmany embodiments, the intraoral scan utilizes a handheld probe formeasuring 3D surface topography by confocal focusing of light beams, forexample, as disclosed in WO 2000/008415, the contents of which areincorporated herein in their entirety. Alternatively, a negativeimpression can be taken of the patient's teeth and scanned using anysuitable method or device, such as by the probe described herein or adesktop scanner. In many embodiments, a positive model is made from thenegative impression and scanned as described herein. For example, astone model can be made from the negative impression and scanned (e.g.,using a probe, desktop scanner, etc.) Alternatively, the 3Dtopographical data can be obtained in any other suitable manner,including other suitable intraoral scanning techniques, based on opticalmethods, direct contact methods or any other means. For example,X-ray-based, CT-based, MRI-based, or any other suitable type of scanningcan be used to produce 3D topographical data of the patient's dentitionand implant.

In step 420, a virtual model of the intraoral cavity is generated withthe 3D topographical data. Any suitable method for producing a 3Dvirtual model from 3D topographical data (e.g., 3D scanning data) can beused, such as a method utilizing suitable computer-aided design (CAD)and/or computer-aided manufacturing (CAM) software. For example, the 3Dtopographical data can be used to determine a virtual surface of the 3Dvirtual model corresponding to intraoral tissues such as teeth orgingiva. The 3D virtual model can be modified to remove various modelelements present in the 3D topographical data that will not berepresented in the unitary dental model. For example, the 3Dtopographical data may include data corresponding to a scan body orimpression body coupled to the implant that is removed prior toperforming the following steps.

Furthermore, the 3D virtual model can be modified to incorporate variousstructures not represented by the 3D topographical data, such as theintegrally formed structures for retaining an abutment and/or fastenersdescribed herein. The integrally formed structures in the virtual modelcan be shaped and oriented to receive and constrain a virtual abutmentmodel (corresponding to the abutment for the implant and/or unitarydental model) at a specified position and orientation. The design of theintegrally formed structures may be determined based on informationregarding the position and orientation of the implant in the intraoralcavity. Such information can be provided, for instance, using data of ascan body or impression body coupled to the implant, as previouslydescribed. Further details on the creation of a virtual model areprovided below.

In step 430, a unitary dental model corresponding to the virtual modelis fabricated. Any suitable fabrication method can be used, such as acomputer-controlled manufacturing process. In many embodiments, asuitable additive manufacturing (AM) process (e.g., stereolithography,3D printing, rapid prototyping) is used to directly fabricate theunitary dental model as a matching physical copy of the virtual model.Alternatively or in combination, a material removing process (e.g., acomputer-controlled material removing process such as computerizednumerical control (CNC) milling) can be used to fabricate the dentalmodel. The fabrication method may be selected based on a desiredfabrication resolution in order to ensure that the surfaces andstructures of the dental model are produced with sufficient accuracy.For example, the fabrication resolution of a suitable fabrication methodmay be approximately 50 μm or less.

In many embodiments, a CNC milling process is used to fabricate theunitary dental model from a milling blank made of a suitable material,such as polyurethane. The CNC milling process may utilize a CNC millingmachine which uses a drill bit (e.g., a 1 mm circular drill bit) toselectively remove material from the blank so as to form the surfacecontours of the unitary dental model. The instructions for controllingthe CNC milling machine may be generated based on the 3D virtual modelincluding the integrally formed structures for retaining an abutmentand/or fasteners described herein (e.g., channel 210, openings 214,216). Optionally, one or more portions of the 3D virtual model may bemodified to ensure proper fit of the abutment with the integrally formedstructures. For example, the 3D virtual model can be adjusted (e.g., bymodifying the size and/or shape of one or more portions; by addingextensions, protrusions, recesses, etc.) to provide a specified minimumclearance between one or more portions of the abutment and thecorresponding portions of the unitary dental model. Alternatively or incombination, the instructions for the milling machine may include asuitable amount of offset from one or more surfaces of the 3D virtualmodel so as to achieve the desired minimum clearance in the resultantdental model. In many embodiments, the minimum clearance between theunitary dental model and the abutment is less than or equal toapproximately 500 μm. The minimum clearance can be selected to ensurethat the abutment can be mounted to the model at the position andorientation defined by the integrally formed structures.

FIG. 5A illustrates a unitary dental model 500 fabricated using a CNCmilling process, in accordance with many embodiments. The unitary dentalmodel 500 includes surfaces 502 corresponding to teeth and gingiva ofthe patient and integrally formed structures 504 for retaining anabutment at a specified position and orientation in the model 500. FIG.5B is a top view of the model 500. The integrally formed structures 504include an opening 506 and a channel having a first portion 508 forreceiving an abutment and a second portion 510 for receiving a fastenerfor the abutment. The first portion 508 can include a cavity 512 shapedto receive a corresponding structure of the abutment. Although thecavity 512 is depicted as a hexagonal shape, other shapes can also beused, such as a circle, triangle, rectangle, square, star, or otherpolygonal shape, as well as suitable combinations thereof. Inembodiments where the cavity 512 is produced by a CNC milling procedure,it may be difficult to fabricate the corners of the cavity 512 withsufficient clearance to permit easy fit of the corresponding abutmentstructure into the cavity. Accordingly, the cavity 512 may be producedwith a plurality of recesses 514 situated at or near the corners of thecavity 512. The configuration of each of the recesses 514 (e.g., size,shape, location) can be adapted to provide additional clearance so as tofacilitate the insertion of the corresponding abutment structure intothe cavity 512.

In step 440, an abutment is mounted to the unitary dental model. Theabutment can be mounted using the integrally formed structures providedherein (e.g., the first portion 218 of the channel 210). The shape andorientation of the integrally formed structures may constrain theabutment to a specified position and orientation when coupled to theunitary dental model, such that the spatial disposition of the abutmentis fixed relative to up to six degrees of freedom of movement.

In step 450, the abutment is secured to the unitary dental model. Inmany embodiments, the abutment is secured to the physical model by oneor more fasteners (e.g., fastener 230 and/or nut 232). Alternatively,the abutment can be secured directly to the model by suitable fasteningstructures integrated into the model (e.g., integrated threading).

In step 460, a dental prosthesis is mounted onto the abutment, usingtechniques known to one of skill in the art.

Although the above steps show method 400 of creating a unitary dentalmodel in accordance with many embodiments, a person of ordinary skill inthe art will recognize many variations based on the teaching describedherein. Some of the steps may comprise sub-steps. One or more steps ofthe method 400 may be performed with any suitable design and fabricationsystem, such as the embodiments described herein. Some of the steps maybe optional, such as one or more of steps 410, 450, or 460. Optionally,some of the steps of the method 400 can be combined. For example, steps420 and 430 can be combined, such that the unitary dental model isfabricated with the 3D topographical data provided in step 410.

FIG. 6 illustrates a method 600 for creating a virtual model of apatient's intraoral cavity, in accordance with many embodiments. Anysuitable system can be used to practice the method, such as the systemsdescribed herein. The steps of the method 600 can be combined orsubstituted with any suitable steps of the other methods disclosedherein.

In step 610, a first virtual model (hereinafter “as-scanned 3D virtualmodel”) that embodies the 3D topographical data of the intraoral cavityhaving the implant is provided. The as-scanned 3D virtual model can becreated from data obtained through any suitable method, such as datagenerated by scanning the patient's intraoral cavity or an impression ofthe patient's intraoral cavity. The scan data may include datacorresponding to a scan body coupled to the implant in the intraoralcavity. In embodiments where an impression of the intraoral cavity isscanned, the scan data may include data corresponding to an impressionof an impression body coupled to the implant. As previously describedherein, the scan data may provide a representation of one or morestructures of the scan body or impression body that enable the positionand orientation of the implant to be determined. Optionally, theas-scanned virtual 3D model can be modified to remove model elementscorresponding to components (e.g., the scan body or impression bodycoupled to the implant) that will not be present in the unitary dentalmodel.

In step 620, the position and orientation of the implant in theas-scanned 3D virtual model is determined. In particular, the positionand orientation of the implant structures that interface with theabutment (e.g., the coupling interface) can be determined. In manyembodiments, the position and orientation is determined using one ormore structures of a scan body or impression body that is coupled to theimplant and scanned with the intraoral cavity, as described above. Forexample, the one or more structures can be identified (e.g., in anautomated, semi-automated, or manual process) and used to position andorient a virtual model of the scan body or impression body relative tothe as-scanned 3D virtual model, such as by registering thecorresponding structures of the scan body or impression body virtualmodel to the identified structures in the as-scanned 3D virtual model.The scan body or impression body virtual model can then be used todetermine the position and orientation of the implant, e.g., byregistering an implant virtual model to the scan body or impression bodyvirtual model. The registration of virtual models to each other may beautomated, semi-automated, or performed manually based on user input.Alternatively or in combination, other structures of the intraoralcavity can be used to locate the implant, such as one or more structuresof a healing abutment coupled to the implant.

In step 630, a virtual model of an implant analog is provided. Thevirtual model can be created from any suitable analog of the implant inthe patient's intraoral cavity and by any suitable method, such as by 3Dtopographical scanning of the implant analog. In many embodiments, theimplant analog and the implant include the same structures that areconfigured to receive and constrain the abutment at a specified positionand orientation.

In step 640, a virtual model of the implant analog is positioned andoriented relative to the as-scanned 3D virtual model so that the implantanalog virtual model matches the position and orientation of the implantin the as-scanned 3D virtual model. The implant analog virtual model maybe located in the as-scanned 3D virtual model based on a previouslydetermined position and orientation of an implant virtual model, asdescribed above. In many embodiments, the implant analog virtual modelis positioned and oriented such that the abutment interfacing structuresof the implant analog virtual model match the position and orientationof the abutment interfacing structures of the implant in the as-scanned3D virtual model. Any suitable method for positioning and orienting theimplant analog virtual model relative to the as-scanned virtual modelcan be used. For example, the implant analog virtual model can bepositioned and oriented relative to the as-scanned virtual model throughan automated process using a computer system having suitable software,such as shape recognition software. Alternatively or in combination, theimplant analog virtual model can be positioned and oriented relative tothe as-scanned virtual model based on user input.

In step 650, a second virtual model (hereinafter “modified as-scannedmodel”) is created by merging the implant analog virtual model with theas-scanned 3D virtual model. Any suitable method for merging virtualmodels can be used. For example, the merge can use suitable computersoftware to combine the virtual models into a single modified-as scannedmodel and remove duplicated model elements.

In step 660, an extraction virtual model can be subtracted from themodified as-scanned model. Any suitable method for subtracting anextraction virtual model from a virtual model can be used. In many, thesubtraction of the extraction virtual model creates one or moreintegrally formed structures (e.g., opening 214, first portion 218 ofchannel 210) in the modified as-scanned model for receiving theabutment, as previously described herein. In many embodiments, theextraction virtual model can be also configured to create one or morestructures (e.g., opening 216, second portion 220 of channel 210) toaccommodate one or more fasteners configured to couple and/or fasten anabutment to a physical model of the modified as-scanned model, aspreviously described herein. Alternatively or in combination, theextraction virtual model can be configured to remove one or more virtualmodel elements corresponding to a body coupled to the implant (e.g., ascan body or impression body).

Although the above steps show method 600 of creating a virtual model inaccordance with many embodiments, a person of ordinary skill in the artwill recognize many variations based on the teaching described herein.Some of the steps may comprise sub-steps. Many of the steps may berepeated as often as appropriate for the modeling process. One or moresteps of the method 600 may be performed with any design and fabricationsystem, such as the embodiments described herein. One or more steps maybe performed based on user input (e.g., from a dental practitioner,technician, etc.). Alternatively or in combination, one or more stepsmay be performed in an automated or semi-automated manner. Some of thesteps may be optional, such as one or more of steps 630, 640, and 650.In many embodiments, the integrally formed structures can be created inthe virtual model without using an implant analog virtual model. Forexample, the integrally formed structures can be shaped, positioned, andoriented in the virtual model based on information regarding the shapeof the abutment and the position and orientation of the implant in thevirtual model. The abutment shape information can be provided using avirtual abutment model (e.g., created from 3D topographical scanning ofthe abutment) that can be combined with the as-scanned 3D virtual modelto create one or more of the integrally formed structures. As anotherexample, the integrally formed structures can be created usinginformation regarding the shape of the implant, such as the shape of thecoupling interface of the implant.

FIG. 7 illustrates a system 700 for creating a unitary dental model, inaccordance with many embodiments. The system can be used to practice anysuitable steps of the methods previously described herein. The system700 can include a scanner 705, a computer system 710, and amanufacturing system 715 for fabricating a unitary dental model havingthe integrally formed structures discussed herein. The scanner 705 canbe any suitable scanner for obtaining 3D topographical data of anintraoral cavity of the patient having a dental implant, such as anintraoral scanner or desktop scanner. The scanner 705 can be operativelycoupled to and controlled by the computer system 710. Alternatively orin combination, the scanner 705 can be controlled by a differentcomputer system, and the data obtained by scanner 705 can be transmittedto computer system 710 through a suitable data transmission method. Forexample, scanning can be performed by scanner 705 in a dental clinic,and the scanning data can be sent to computer system 710 at a facilityremote to the dental clinic.

The computer system 710 can include an input interface 720 (e.g., amouse, a keyboard, or a touch screen), an output device or display 725(e.g., a screen, a monitor, or a printer), a processing unit 730, and amemory 735. The memory 735 can include memory storing instructions thatcan be executed by the processing unit 730. The computer system 710 caninclude suitable software (e.g., virtual modeling software) for creatinga virtual model from the 3D topographical data obtained by scanner 705.For example, the memory storing instructions can include suitablecomputer code to be executed by the processing unit 730 to create avirtual model in accordance with the methods provided herein. Theinstructions can also include suitable computer code to be executed bythe processing unit 730 to generate output for controlling amanufacturing system 715 to fabricate a unitary dental model having theintegrally formed structures described herein.

The manufacturing system 715 can include a computer-controlledmanufacturing system configured for manufacturing a physical dentalmodel from a virtual model based on output from the computer system 710.Any suitable computer-controlled manufacturing system can be used, suchas a manufacturing system suitable for performing stereolithography, 3Dprinting, CNC milling, and the like. The manufacturing system 715 can becontrolled by one or more processors of any suitable computer system,such as the computer system 710. Alternatively or in combination, themanufacturing system 715 can be controlled by a different computersystem than the computer system 710, and the data output by computersystem 710 can be transmitted to the manufacturing system 715 by asuitable data transmission method. For example, the computer system 710can be used to create a virtual model at a modeling facility, and thevirtual modeling data can be transmitted to a remote manufacturingfacility to control manufacturing system 715.

The various techniques described herein may be partially or fullyimplemented using code that is storable upon storage media and computerreadable media, and executable by one or more processors of a computersystem. The processor can comprise array logic such as programmablearray logic (hereinafter PAL), configured to perform the techniquesdescribed herein. Storage media and computer readable media forcontaining code, or portions of code, can include any appropriate mediaknown or used in the art, including storage media and communicationmedia, such as but not limited to volatile and non-volatile, removableand non-removable media implemented in any method or technology forstorage and/or transmission of information such as computer readableinstructions, data structures, program modules, or other data, includingRAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM,digital versatile disk (DVD) or other optical storage, magneticcassettes, magnetic tape, magnetic disk storage or other magneticstorage devices, or any other medium which can be used to store thedesired information and which can be accessed by the a system device.Based on the disclosure and teachings provided herein, a person ofordinary skill in the art will appreciate other ways and/or methods toimplement the various embodiments.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. It should be understoodthat various alternatives to the embodiments of the invention describedherein may be employed in practicing the invention. It is intended thatthe following claims define the scope of the invention and that methodsand structures within the scope of these claims and their equivalents becovered thereby.

1. (canceled)
 2. A non-transitory computing device readable mediumstoring instructions executable by a processor configured to cause acomputing device to perform a method for creating a unitary dentalmodel, comprising: receiving topographical data of an intraoral cavityof a patient having a dental implant; determining a position and anorientation of the dental implant in an as-scanned virtual model thatembodies the topographical data of the intraoral cavity; positioning avirtual model of an implant analog relative to the as-scanned virtualmodel based on the determined position and orientation of the dentalimplant; modifying the as-scanned virtual model by merging the implantanalog virtual model with the as-scanned virtual model, thereby creatinga modified as-scanned virtual model; and generating instructions forfabricating the unitary dental model based on the modified as-scannedvirtual model.
 3. The non-transitory computing device readable medium ofclaim 2, wherein the processor is further configured to cause afabrication device to directly fabricate the unitary dental model basedon the instructions generated.
 4. The non-transitory computing devicereadable medium of claim 2, wherein the instructions for fabricating theunitary dental model comprises using additive manufacturing to directlyfabricate unitary dental model.
 5. The non-transitory computing devicereadable medium of claim 2, wherein the unitary dental model comprises:a physical surface representative of gingival tissue of the patient, anda channel extending through the unitary dental model and shaped andoriented to receive an abutment corresponding to receive an abutmentcorresponding to a physical abutment to be connected to the dentalimplant, wherein the channel extends to an opening in the physicalsurface.
 6. The non-transitory computing device readable medium of claim5, wherein the channel comprises a first portion and a second portion,the first portion shaped to receive and constrain a correspondingstructure of the abutment to a position and orientation and having ashape complementary to the shape of the abutment, the second portionshaped to receive a fastener to couple the abutment to the unitarydental model.
 7. The non-transitory computing device readable medium ofclaim 6, wherein the first portion of the channel comprises a shouldershaped to receive the corresponding structure of the abutment in orderto position the abutment along the channel, wherein the shoulder extendsfrom a surface of the first portion to a surface of the second portion,the shape of the first portion constrains the corresponding structure ofthe abutment to the position and orientation while the shoulder is incontact with the corresponding structure of the abutment.
 8. Thenon-transitory computing device readable medium of claim 6, wherein theinstructions executable by the processor further causes the computingdevice to: modifying one or more portions of the modified as-scannedmodel in order to provide a desired amount of clearance between thefirst portion and the corresponding structure of the abutment.
 9. Thenon-transitory computing device readable medium of claim 6, wherein thefirst portion is shaped to correspond to a portion of the dental implantthat receives and constrains a corresponding structure of the physicalabutment.
 10. The non-transitory computing device readable medium ofclaim 6, wherein the second portion extends to an opening in a bottomsurface opposite the physical surface, and wherein the opening in thebottom surface is shaped to accommodate a nut for securing the abutmentand fastener to the unitary dental model.
 11. The non-transitorycomputing device readable medium of claim 6, wherein the first portionis shaped to receive and constrain the corresponding structure of theabutment to a predetermined position and orientation.
 12. Anon-transitory computing device readable medium storing instructionsexecutable by a processor to cause a computing device to perform amethod for creating a unitary dental model, comprising: receivingtopographical data of an intraoral cavity of a patient having a dentalimplant; an as-scanned virtual model that embodies the topographicaldata of the intraoral cavity; positioning a virtual model of an implantanalog relative to an as-scanned virtual model that embodies thetopographical data of the intraoral cavity; modifying the as-scannedvirtual model by merging the implant analog virtual model with theas-scanned virtual model, thereby creating a modified as-scanned virtualmodel; and generating instructions for fabricating the unitary dentalmodel based on the modified as-scanned virtual model.
 13. Thenon-transitory computing device readable medium of claim 12, wherein theprocessor is further configured to cause a fabrication device todirectly fabricate the unitary dental model based on the instructionsgenerated.
 14. The non-transitory computing device readable medium ofclaim 12, wherein the instructions for fabricating the unitary dentalmodel comprises using additive manufacturing to directly fabricateunitary dental model.
 15. The non-transitory computing device readablemedium of claim 12, wherein the unitary dental model comprises: aphysical surface representative of gingival tissue of the patient, and achannel extending through the unitary dental model and shaped andoriented to receive an abutment corresponding to receive an abutmentcorresponding to a physical abutment to be connected to the dentalimplant, wherein the channel extends to an opening in the physicalsurface.
 16. The non-transitory computing device readable medium ofclaim 15, wherein the channel comprises a first portion and a secondportion, the first portion shaped to receive and constrain acorresponding structure of the abutment to a position and orientationand having a shape complementary to the shape of the abutment, thesecond portion shaped to receive a fastener to couple the abutment tothe unitary dental model.
 17. The non-transitory computing devicereadable medium of claim 16, wherein the first portion of the channelcomprises a shoulder shaped to receive the corresponding structure ofthe abutment in order to position the abutment along the channel,wherein the shoulder extends from a surface of the first portion to asurface of the second portion, the shape of the first portion constrainsthe corresponding structure of the abutment to the position andorientation while the shoulder is in contact with the correspondingstructure of the abutment.
 18. The non-transitory computing devicereadable medium of claim 16, wherein the instructions executable by theprocessor further causes the computing device to: modifying one or moreportions of the modified as-scanned model in order to provide a desiredamount of clearance between the first portion and the correspondingstructure of the abutment.
 19. The non-transitory computing devicereadable medium of claim 16, wherein the first portion is shaped tocorrespond to a portion of the dental implant that receives andconstrains a corresponding structure of the physical abutment.
 20. Thenon-transitory computing device readable medium of claim 16, wherein thesecond portion extends to an opening in a bottom surface opposite thephysical surface, and wherein the opening in the bottom surface isshaped to accommodate a nut for securing the abutment and fastener tothe unitary dental model.
 21. The non-transitory computing devicereadable medium of claim 16, wherein the first portion is shaped toreceive and constrain the corresponding structure of the abutment to apredetermined position and orientation.
 22. A method for creating aunitary dental model, comprising: receiving topographical data of anintraoral cavity of a patient having a dental implant; positioning avirtual model of an implant analog relative to an as-scanned virtualmodel that embodies the topographical data of the intraoral cavity;modifying the as-scanned virtual model by merging the implant analogvirtual model with the as-scanned virtual model, thereby creating amodified as-scanned virtual model; and generating instructions forfabricating the unitary dental model based on the modified as-scannedvirtual model.
 23. The method of claim 22, further comprising causing afabrication device to directly fabricate the unitary dental model basedon the instructions generated.
 24. The method of claim 22, wherein theinstructions for fabricating the unitary dental model comprises usingadditive manufacturing to directly fabricate unitary dental model. 25.The method of claim 22, wherein the unitary dental model comprises: aphysical surface representative of gingival tissue of the patient, and achannel extending through the unitary dental model and shaped andoriented to receive an abutment corresponding to receive an abutmentcorresponding to a physical abutment to be connected to the dentalimplant, wherein the channel extends to an opening in the physicalsurface.
 26. The method of claim 25, wherein the channel comprises afirst portion and a second portion, the first portion shaped to receiveand constrain a corresponding structure of the abutment to a positionand orientation and having a shape complementary to the shape of theabutment, the second portion shaped to receive a fastener to couple theabutment to the unitary dental model.
 27. The method of claim 26,wherein the first portion of the channel comprises a shoulder shaped toreceive the corresponding structure of the abutment in order to positionthe abutment along the channel, wherein the shoulder extends from asurface of the first portion to a surface of the second portion, theshape of the first portion constrains the corresponding structure of theabutment to the position and orientation while the shoulder is incontact with the corresponding structure of the abutment.
 28. The methodof claim 26, further comprising: modifying one or more portions of themodified as-scanned model in order to provide a desired amount ofclearance between the first portion and the corresponding structure ofthe abutment.
 29. The method of claim 26, wherein the first portion isshaped to correspond to a portion of the dental implant that receivesand constrains a corresponding structure of the physical abutment. 30.The method of claim 26, wherein the second portion extends to an openingin a bottom surface opposite the physical surface, and wherein theopening in the bottom surface is shaped to accommodate a nut forsecuring the abutment and fastener to the unitary dental model.
 31. Themethod of claim 26, wherein the first portion is shaped to receive andconstrain the corresponding structure of the abutment to a predeterminedposition and orientation.